2004 YAMAHA VERSITY 300 Owners Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Periodic maintenance and lubrication chart
NOTE :
•The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
•From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
•Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
1 * Fuel line•Check fuel hoses and vacuum hose for cracks or damage.√√√√ √
•Check condition.
√√
2 Spark plug•Clean and regap.
•Replace.√√
3 * Valves•Check valve clearance.
√√
•Adjust.
4 Air filter element•Clean.√√•Replace.√√
5 V-belt case air filter element•Clean.√√√√
•Check operation, fluid level and vehicle for fluid leakage.
√√√√√ √
6 * Front brake(See NOTE on page 6-4.)
•Replace brake pads. Whenever worn to the limit
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
10 20 30 40
6-2

PERIODIC MAINTENANCE AND MINOR REPAIR
6
•Check operation, fluid level and vehicle for fluid leakage.
√√√√√ √7 * Rear brake(See NOTE on page 6-4.)
•Replace brake pads. Whenever worn to the limit
8 * Brake hoses•Check for cracks or damage.√√√√ √•Replace. (See NOTE on page 6-4.) Every 4 years
9 * Wheels•Check runout and for damage.√√√√
•Check tread depth and for damage.
10 * Tires•Replace if necessary.
√√√√ √
•Check air pressure.
•Correct if necessary.
11 * Wheel bearings•Check bearing for looseness or damage.√√√√
12 * Steering bearings•Check bearing play and steering for roughness.√√√√√•Lubricate with lithium-soap-based grease. Every 20,000 km
13 * Chassis fasteners•Make sure that all nuts, bolts and screws are
√√√√ √
properly tightened.
14 Sidestand, Centerstand•Check operation.
√√√√ √
•Lubricate.
15 * Sidestand switch•Check operation.√√√√√ √
16 * Front fork•Check operation and for oil leakage.√√√√
17 * Shock absorber assemblies•Check operation and shock absorbers for oil leakage.√√√√
18 * Carburetor•Adjust engine idling speed.√√√√√ √
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
10 20 30 40
6-3

PERIODIC MAINTENANCE AND MINOR REPAIR
6
•Change. (See page 3-7 for more information about the√When the oil change indicator comes on19 Engine oil oil change indicator)( Every 3000 km)
•Check oil level and vehicule for oil leakage. Every 3,000 km√
20 * Engine oil strainer•Clean.√
21 * Cooling system•Check coolant level and vehicule for coolant leakage.√√√√ √•Change. Every 3 years
22Final transmission oil•Check vehicle for oil leakage.√√ √•Change.√√√
23 * V-belt•Replace. Every 20,000 km
24 *Front and rear brake
•Check operation.√√√√√ √
switches
25 Moving parts and cables•Lubricate.√√√√ √
Throttle grip housing•Check operation and free play.
26 *
and cable•Adjust the throttle cable free play if necessary.√√√√ √
•Lubricate the throttle grip housing and cable.
27 *Lights, signals•Check operation.
√√√√√ √
and switches•Adjust headlight beam.
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
10 20 30 40
EAU03884*
NOTE :
•The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
•Hydraulic brake service
•Regularly check and, if necessary, correct the brake fluid level.
•Every two years change the brake fluid.
•Replace the brake hoses every four years and if cracked or damaged.
6-4

PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Removing and installing
cowlings and panels
The cowlings and panels shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter. Refer to this section each
time a cowling or panel needs to be
removed and installed.
1
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1. Cowling A 1. Cowling B
6-5
1
2
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1. Windshield
2. Panel A

PERIODIC MAINTENANCE AND MINOR REPAIR
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1
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1
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1. Panel B 1. Panel C
6-6
1
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1. Panel D

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Cowling A
2. Screw (x 8)
3. Floorboard mat (x2)1. Turn signal lead coupler
2. Headlight coupler
6-7
3 2 1
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Cowling A
To remove the cowling
1. Pull up the floorboard mat on each
side of the scooter.
2. Remove panel A. (See page 6-9
for removal and installation
procedures.)
3. Remove the cowling screws.4. Disconnect the headlight coupler
and the turn signal lead coupler.
5. Pull the cowling off.
To install the cowling
1. Connect the headlight coupler,
and the turn signal lead coupler.
2. Place the cowling in the original
position, and then install the
screws.
3. Install panel A.
4. Place the floorboard mats in their
original position.
1
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1. Panel E

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Floorboard mat (x2)
1. Screw (x 4)
2. Cowling B 1. Screw (x5)
2. Cowling B
6-8
1
2
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1
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1
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Cowling B
To remove the cowling
1. Pull up the floorboard mat on each
side of the scooter.2. Remove the screws on each side
of scooter, and then take the
cowling off.To install the cowling
1. Place the cowling in the original
position, and then install the
screws.
2. Place the floorboard mats in their
original position.

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Windshield
2. Screw (x4)1. Screw (x2)
2. Panel A
6-9
2 1
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1
2
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Panel A
To remove the panel
1. Remove the screws, and then take
the windshield off.2. Remove the screws, and then pull
the panel out as shown.
To install the panel
1. Place the panel in the original po-
sition, and then install the screws.
2. Place the windshield in the origi-
nal position, and then install the
screws.
EAU01535
Panel B
To remove the panel
Remove the screw, and then pull the
panel off as shown.
To install the panel
Place the panel in the original position,
and then install the screw.
1. Screw (x1)
2. Panel B
1
2
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